116-3028, 116-3018 X-Pando Pre-Adjusted Steel Protector
Installation Instructions
1404 N. Marshall Ave. El Cajon CA. 92020
For technical support call us at (800) 368-3075 v
607-0113
NB 6/28/10
Step 1. Mounting Positions
Determine the mounting position for your truck Fig. 1 - Fig. 8.
Fig. 1
Fig. 3
Fig. 2
“A” Mount Bottom Roll
Fig. 4
“B” Mount Bottom Roll
Fig. 6
Fig. 5
“E” Mount Bottom Roll
“D” Mount Bottom Roll
Fig. 7
“C” Mount Bottom Roll
“F” Mount Bottom Roll
Fig. 8
“B” Brackets
NOTE: Use optional “B” Brackets when
mounting in position “B” and “E”.
“G” Mount Top Roll
2
Fig. 9
Step 3.
Fig. 10
Weld Mounting
Bar to Truck
Remove this bolt.
Insert 3/8” x 2”
bolt through hole
Step 2.
Weld System To Truck
Stitch weld system mounting
bar to truck every 6” as
shown in (Fig. 10)
Step 4. Dimple Tailgate for Rope Guide
Check the top of the tailgate where your tarp goes over for any obstructions
that may interfere with the tarp laying flat all the way across the tailgate area.
WARNING: Sharp Edges May Cut Tarp.
Measure tailgate to find center and mark. Heat at mark with torch until area
is red hot. Use a 3/4” diameter solid bar and lay it on the spot and strike it a
few times. A smooth indentation should be left that will keep the rope
centered. (Fig. 11) & (Fig. 12)
Remove Tarp Before Welding
*Before welding remove tarp to avoid damage (Fig. 9)*
Remove the 7/16” x 1/2” bolt from the ratchet cover plate.
WARNING: Do not remove the four Phillips head screws
from the ratchet cover plate. Insert 3/8” x 2” bolt through
hole in ratchet cover plate and into groove in roller tube. Slide
tarp out of housing and away from work area.
Fig. 11
Fig. 12
Step 5. Weld on Tarp Return Ramps
The Tarp Return Ramps hold the pullrod in place once the tarp has been deployed. The ramps should be welded as high as possible.
See (Fig. 13 & Fig. 14 for your application). Make sure all rough edges are ground smooth. If you have a raised hinge you will need to
add a Hinged Ramp Gusset (NOT SUPPLIED) see (Fig.15).
Fig. 13
Tarp Return Ramp
Fig. 14
Tarp Return Ramp
Fig. 15
Hinge Ramp Gusset
Tarp Return Ramp
3
Step 6.Tarp Return Ramps for Belly Dumps
All belly dumps require special tarp return ramps. If you are
not sure which type to use, call us at Pulltarps (800) 368-3075
for technical support.
Jump Ramp
On longer single units, you are too far from the return ramp to
unlatch the Pullrod by hand so we developed the easy to
operate Jump Ramp (Fig. 16). Pull the tarp out all the way.
Lower your arm. Release some rope slowly and allow the
Pullrod to slide forward and drop down into the Tarp Return
Ramp.
1. Pull out and hook. (Fig. 17).
Fig. 16
2. To retract, pull the pullrod up over the
jump-ramp gusset and down a few inches
(Fig. 18).
Fig. 17
3. Release a few feet of rope quickly and
the spring in the roller will cause the Pullrod
and tarp to jump over the return ramp and
retract back to the system (Fig. 19).
Fig. 18
On long belly dumps with short vertical sideboards, use the
finger tarp return ramps. Weld the provided gussets to the
box to create a Pullrod jump ramp (Fig. 20).
Fig. 20
Fig. 19
On short belly dumps, pull the tarp all the way out. Raise
and lower to hook and unhook the Pullrod over the finger
tarp return ramps (Fig. 21).
Fig. 21
4
Fig. 22
rp
Ta
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Sli
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arp
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id
w
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id
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ide wid
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Fig. 23
Step 7. Install Tarp
The pull rod assembly will need to be two inches wider than the outside width of the
body at its widest point, or the outside width of the tarp housing which ever is greater.
Adjust pull rod length by cutting equal amounts from each end of the pull rod (Fig. 22)
Step 8. Install Tarp
Slide the tarp into the groove in the roller
tube from the right side. Center the tarp on
the roller tube. If needed, lubricate the edge
of the tarp with soapy water so it will slide
into the roller slot easy. (Fig. 23)
Step 9.
Slide the pull rod on to the end of the tarp so
that the sleeve is centered with the webbing
for the pull rope.
Install the pull rope on the tarp . Put the loop
of the rope through the webbing and then pass
the bungee end of the rope through the open
loop of the rope. Pull the rope through until the
loop
closes tightly around the webbing strap.
(Fig. 24)
Fig. 24
5
Step 10. Pull the tarp out as far as possible and tie off at tailgate.
Remove ratchet lock and turn ratchet clockwise 25 turns (Fig. 25).
Release pull rope from tail gate and cycle the tarp in and out 2 or 3 times.
The tarp must be pulled out all the way before additional spring tension can be added.
Turn ratchet nut clockwise 5 turns at a time to add more tension if necessary.
Test tension setting after every adjustment reinstall ratchet lock
SETTING SPRING TENSION
To Increase Tension
1. Pull Tarp out as far as possible and tie off at tail gate.
2. Remove Ratchet Lock. Turn ratchet nut clockwise 5 turns at a time.
3. Test operation and repeat steps 1 through 3 if necessary.
4. Reinstall the Ratchet Lock
To Decrease Tension
1. Remove Ratchet Lock. Place box and wrench on ratchet nut. Turn ratchet nut slightly to the right and don’t let go
2. Insert screwdriver to disengage lever. Hold wrench with both hands slowly unwind spring pressure.
3. When desired tension is achieved remove screw driver allowing release lever to reengage ratchet gear.
Fig. 25
Re To D
Ins mov isen
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Sc atc e L
rew he ev
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ase
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1. Re sion:
m
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2. Rem le and tie ofr as
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turns
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if nece
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atch
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ock
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Re To D
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Sc atc e L
rew he ev
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He
re
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ase
Ten
1. Re sion:
m
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ratc d wren ce box
ratc het nut. ch on
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let goe right a ightly
nd d
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Step 11. Release pullrope from tailgate and cycle the tarp 2 or 3 times. This will ensure the tarp rolling up straight. If the tarp rolls up consistently off to one side or the other, you can offset the tarp to the opposite side on the roller to start with, this way the tarp will roll up as centered as possible. If you have side flaps or tie downs proceed to steps 12 through 14.
Step 12.Rope Storage Hook
Fig. 26
Fig. 27
Installation
Mount the rope as low as
possible. The rope should
Rope Storage
come straight down and wrap
Hooks
around the center hook and
Rope Storage Hooks
then coil off to the side. When the tarp is not in use (Fig. 26). Space the hooks far enough apart to store the full length of rope (Fig. 27).
Note: Tarp must be retracted when dumping.
6
Te
1. Pull
nsion:
ta
possib rp out as
fa
2. Rem le and tie ofr as
ov
f
ratche e Ratche at t
t
at a timt nut clockwLock.
ise 5
3. Test e.
operat
ion an
d
1 thro
ugh 3 rep
if ne
Insta
ll R
atch
Step 13.Optional Tie Down Tarp, Rope and Hook Installation
Fig. 28
Parts: Tie Down Hooks (Steel or Alum.)
Pull Down Hook
The Location Of The Tie Down Hooks Is Critical !
Flip the braided rope over the corner so that the rope and tie down flaps hang over
each side of the box. The number of tie down hooks vary depending on the length of
your tarp. One pull down hook is included with your Pulltarp system. If needed. Use
the hook to pull the braided rope and tie down flap over the side of the box.
2”
The tie down hooks must be positioned so that:
a. b. c.
d. The
The
The
The
Fig. 29
tie down rope can be reached from the ground.
bungee cord has to be stretched to reach the last hook (see step 10).
rope has no slack.
tie down hooks are level with one another.
Center
To ensure proper hook placement, first duct tape the rope to the box in place
of the tie down hooks. Start with hook closest to the cab.
1.
2.
3.
4. Position the first hook 2” (5.08cm) forward of first
tie down (Fig. 28).
Position middle hook between tie downs (Fig. 29).
Position last hook at the end of the box (Fig. 30).
Weld hooks in place level with one another.
Fig. 30
Correct
Incorrect
7
Step 14.Optional Flap Tarp, Rope and Hook Installation
Fig. 31
Parts: Tie Down Hooks (Steel or Alum.)
Pull Down Hook
The Location Of The Tie Down Hooks Is Critical !
Flip the braided rope over the corner so that the flaps and tie down ropes hang over
each side of the box. The number of tie down hooks vary depending on the length of
your tarp. One pull down hook is included with your Pulltarp system. If needed. Use
the hook to pull the braided rope and flap over the side of the box.
Fig. 32
The tie down hooks must be positioned so that:
a. b. c.
d. The
The
The
The
tie down rope can be reached from the ground.
bungee cord has to be stretched to reach the last hook (see step 9).
rope has no slack.
tie down hooks are level with one another.
To ensure proper hook placement, first duct tape the rope to the box in place
of the tie down hooks. Start with hook closest to the cab.
1.
2.
3.
4.
5.
Fig. 33
Position the first hook 6” (15.24cm) down and 12” (30.48cm)
forward (toward the cab) from the first grommet (Fig. 31).
Position 2nd hook straight down from 1st
grommet. This hook should be reached from ground (Fig. 32).
Place middle hooks equal distances from
grommet (Fig. 33). These hooks should be placed at the same height
as the second hook.
Position last hook (closest to the tailgate) below the last grommet
at the same height as the others (Fig. 34).
Weld hooks in place.
Fig. 34
CORRECT
INCORRECT
8
Step 15. Bungee Cord Installation
Connect Bungee Cord to Rope
After side hooks are installed, the tie down rope must be
installed and cut to proper length. It is important to get all
of the slack out of the rope to prevent blowing and rubbing of flaps in windy conditions.
Parts:
2 Bungee Cords,
2 Oval Compression sleeves,
1. Thread braided rope through Oval
Compression Sleeve.
1.
2. Feed rope through the eye of the
bungee cord.
2.
3. Thread the rope back through the oval
compression sleeve. Adjust for proper length. Crimp compression sleeve.
3.
1 Snap Clip
Tarps with Tie Downs
Tarps with Side Flaps
To tighten, pull loose end of rope through the Oval
Compression Sleeve (Fig. 35). Stretch the bungee cord
making sure all slack is taken out of the rope, crimp compression sleeve (Fig. 36).
To tighten, pull loose end of rope through the Oval Compression Sleeve
(Fig. 37). Stretch the bungee cord making sure all slack is taken out of
the rope, crimp compression sleeve (Fig. 38).
Note: Check for proper placement of rope through the last two hooks.
Fig.36
Fig.35
Fig.37
Fig.38
Snap Clip installation
Excess Rope
Flip the rope back on top of the tarp, making sure to hold the bungee at all times.
The first snap clip is factory installed 5’-6” from the pullrod. Open the clip and
enclose the rope. Weave the second clip through the main pullrope where the ends
of the bungee cords meet the main pullrope. Make sure the rope is taught when
clipped. NOTE: First snap clip should not be used on long wheel base belly dumps.
You may need extra rope to keep the side flap system ground
operated. If your application requires extra rope, the slack needs to
be taken up by attaching the end of the bungee cord to an alternate
hook. (pictured below)
Tailgate
2nd Snap Clip
1st Snap Clip
Top View
9
116-3028, 116-0318 X- Pando Adjustable Steel Protector
2
A
1
3
9
11
10
17
12
20
3
4
8
16
6
13
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
1
501-0167
76" TELESCOPE STEEL PROT. CENTER HSG.
1
2
501-0168
14" STEEL PROTECTOR ADJ. END (LEFT)
1
3
501-0169
14" STEEL PROTECTOR ADJ. END (RIGHT)
1
4
501-0280
LARGE TELESCOPE RATCHET END PLATE
1
5
501-0281
LARGE TELESCOPE END PLATE PASS.
1
6
501-1550
51" MOUNTING BAR-STEEL
2
7
501-0138
GALVANIZED INSERT
1
8
506-9905
10-32 X 1/2" PHILLIPS PAN HEAD SCREW
4
9
503-2501
1/4-20 X 1/2" USS CARRIAGE BOLT
22
10
504-2506
1/4" HEX LOCK NUT "THIN"
22
11
505-2502
1/4" USS WASHER 5/16" HOLE
22
12
505-3102
5/16" Lock Washer
14
13
503-3101
5/16 - 18 x 1/2" hex bolt
14
4
14
503-2502
1/4-20 X 1/2" SS BUTTON HD SCREW
15
504-2504
1/4"-20 WELD NUT - SINGL
4
16
501-1504
5" Mounting Bar (STL)
2
17
501-0647
SYSTEM END PLATE RATCHET ASSEMBLY
1
18
501-1363
ADJUSTABLE ROLLER TUBE ASSY
1
SYSTEM END PLATE STUD 2.4"
1
19
501-0801
20
505-5002
21
504-5001
1/2" CRIMP NUT
1
22
505-5001
1/2" AN FLAT WASHER
1
Nylon Washer .51 ID x 1.25 OD x .063 thick
2
10